automated multi-spindle drilling line<\/a><\/strong> in 1965 there have been significant enhancements in drilling feed rates and positioning speeds of both the material being processed and the drill spindle axis performance. The process to increase the drill lines efficiency and eliminate non-productive cycles has perhaps plateaued for the moment with the sub-axis spindle positioning to enhance the \u201cchip to chip\u201d time.<\/p>\nFICEP\u2019s focus, since it\u2019s first fully automated material handling system in 1988, has been to enhance the efficiency of the material flow through the line.<\/strong><\/p>\nThe challenge was to increase the percentage of time that the work centers (sawing, drilling, scribing, coping, milling, thermal cutting and shot blasting) are actively engaged in processing and not waiting to start the next section.<\/p>\n
How is the Optimum Layout Determined?<\/h2>\n
There are no two structural steel fabrications firm\u2019s facilities that are identical. The combination of a plant\u2019s layout, product mix, required processes and the needed throughput makes the challenge of designing the optimum layout unique. Actual past jobs of different types are downloaded to generate a specific productivity report based upon the type of contract.<\/p>\n
Until FICEP developed \u201cSystem Simulation\u201d<\/strong> the engineering of a plant layout was typically based upon an interview process with the client. The goal was to try to achieve a layout that was the result of some educated guesses and assumptions. Today, FICEP uses proprietary software to evaluate how different job types and plant layouts can be simulated for a detailed productivity analysis.<\/strong><\/p>\nSplit work cells versus tandem systems, transfer tables capabilities\/features and the material buffer zones sizes are just some of the variables that require evaluation.<\/p>\n
\u201cSystem Simulation\u201d is a process where potential layouts are evaluated based upon the manpower requirements, capabilities, throughput and bottlenecks. Actual jobs and or sequences are imported into the PLM software that starts with material nesting and uses powerful algorithms to sequence the production in the most efficient fashion. Once the optimized workload is downloaded, the \u201cSystem Simulator\u201d shows the processing of the mults and finished parts in a 3D video mode to reflect the actual process times required to fabricate this production release. The \u201cSystem Simulator\u201d shows where bottlenecks develop and identifies work centers that can be underutilized waiting for material to fabricate. This innovative process enables different layout designs to be compared and further modified to determine which design achieves the maximum flexibility and productivity.<\/strong><\/p>\nHow does \u201cSystem Simulation\u201d enhance your daily productivity?<\/h2>\n
Once the preliminary shop loading for the structural steel fabricating line is determined, the software\u2019s algorithms develop the optimum sequences of the selected production release. Prior to starting the actual production, the \u201cSystem Simulation\u201d can identify possible bottlenecks and any under utilized work centers. Once determined this innovative software can show how the systems total productivity can be increased by modifying or adding to the pending production release.<\/p>\n
How does Intelligent Steel Fabrication function?<\/h2>\n
As the multed sections are loaded onto the line the material handler scans into the system the corresponding bar code from the cut list.<\/p>\n
The sections are automatically positioned without an operator or attendant through the system. The path through the line or routing to the appropriate work cells is based upon the required processes and the optimum utilization of the systems capabilities. As a mult or cut part enters each work cell the stock length is verified and the appropriate CNC program is automatically selected to process the required objectives.<\/p>\n
Benefits<\/h2>\n
The benefits of \u201cIntelligent Steel Fabrication\u201d are numerous and cost effective. Most of the systems sold and installed by FICEP today feature \u201cIntelligent Steel Fabrication\u201d capability, as the benefits are extensive and easily justifiable as this automation cost represents a minimal investment as a percentage of the total systems cost.<\/p>\n
Benefits Summary<\/p>\n
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Reduction in skill level in the workshop<\/p>\n<\/li>\n
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Increased efficiency (loading\/unloading\/scrap handling done in masked time)<\/p>\n<\/li>\n
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Less hours required per ton (human down times goes to zero for manual handling)<\/p>\n<\/li>\n
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Production gains (gains from 30 to 50% just for automation in the handling)<\/p>\n<\/li>\n
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Fewer mistakes (auto ID) of the beam types and size all areas are managed<\/p>\n<\/li>\n
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Added value to process more efficiently<\/p>\n<\/li>\n
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Positive bottom line<\/p>\n<\/li>\n<\/ul>\n